CA1157755A

CA1157755A - Method and apparatus for heat sealing

Info

Publication number: CA1157755A
Application number: CA000352311A
Authority: CA
Inventors: James L. Hutcheson
Original assignee: Reynolds Metals Co
Current assignee: Reynolds Metals Co
Priority date: 1979-09-14
Filing date: 1980-05-16
Publication date: 1983-11-29

Abstract

Application of James L. Hutcheson (Docket No, 6825) For UNITED STATES LETTERS PATENT
On METHOD AND APPARATUS FOR HEAT SEALING

ABSTRACT OF THE DISCLOSURE

A method and apparatus for heat sealing flexible containers, and particularly pouch-like containers, is disclosed. A filled pouch is positioned between a pair of heated bars, with the bars being constructed and arranged to maintain a gap therebetween when they are closed, such that sealing pressure is not applied to the pouch.
Thereafter, the pouch is positioned between a pair of chilled sealing bars and the chilled bars are closed to apply sealing pressure to the edge of the pouch, where the edge region of the pouch is sealed and cooled. If desired, a plurality of gapped heated bar stations may be provided prior to the chill bar position.

Description

~ 157755 ~ his invention relates to a method and apparatus for heat sealing a flexible container.
Numerous materials are packaged in flexible containers, such as flexible pouch-like containers. Such pouches may be formed from pairs of webs which are heat sealed to one another, or the pouch may be formed of a single web which is folded, with the side seams and top seam, and optionally the folded bottom edge, being heat sealed. Such pouch-li~e containers may be fabricated from thermoplastic resins or laminates including inner heat-sealable layers fabricated from thermoplastic resins. Thus, pouches are commonly formed from a pair of lamina in which each lamina comprises an outer layer of a plastics resin film, a central barrier layer of a metal foil, such as aluminum foil, and an inner layer of a heat-sealable thermoplastic resin film or from folded webs of these sheet materials.
ln filling and sealing pouches with food-stuffs and the like, contamination of the top edge region of the pouch, which is the area where the final seal is to ~e formed, is a continuing pro~lem.
Quite often, solid food particles will cling to the walls of the pouch in the edge region where this heat seal is to be located. This contamination requires that the region to ~e heat sealed be cleaned of food particles prior to sealing, since these particles will interfere with the heat sealing operation, causing gaps, blisters, blemishes or other defects in the heat seal and possi~le failure in the seal. Such cleaning has in the past ~een accomplished by means of pressurized ~.~

~ 157755 steam. While pressurized steam successfully cleanses the edge region which is to be heat sealed from solid food particles, the steam which is employed presents a sealing problem of its own. Moisture now present in the heat seal region can cause blister defects in the seal, due to entrapment of the moisture in the sealing region and the conversion of this moisture in the sealing region to steam under pressure by the heated pressurizing sealing bars, and thus also cause failures in the heat seal. Thus, it is a primary object of the present invention to improve the final heat seal formed on a filled pouch by elimination of these moisture-caused defects.
The present invention provides the desired improvement in forming the final heat sealed edge for a filled pouch.
The method of the present invention comprises positioning a flexible container, particularly a pouch, between a pair of heated bars, closing the bars, with the pouch therebetween, while maintaining a gap between the bars such that heat-sealing pressure isnot applied to the heat sealing region of the pouch, positioning the pouch between a pair of chilled sealing bars and closing the chilled bars, with the heated region of the pouch therebetween, to app~y sealing pressure to the heated sealing region of the pouch while sealing and cooling this region. Optionally, the pouch may be positioned between additional pairs o~ gapped heated bars prio~ to final sealing at the chilled bars.
~he apparatus of the present invention comprises the pair or pairs of gapped heated bars, ~ 15775~
the pair of chilled sealing bars and the means for positioning the pouch between the bar pairs.
Employment of the method a~d apparatus of the present invention provides heat seals which are free from defects due to moisture and which will seal through contaminates which are not entirely removed by the cleaning operation, such as grease, consistently.

.
~RIEF_DESCRIPTION OF THE DRAWINGS
The method and a pparatus of the present invention will be more fully described with reference to the drawings in which~
FIGURE 1 is a schematic view of a pouch - filling and sealing line employing the method and apparatus of the present invention;
FIGURE 2 illustrates the positioning of ' the pouch between a pair of heated bars prior to closing of the bars: ~
PIGURE 3 illustrates the pouch positioned between the heated bars with the bars in their closed position;
PIGURE 4 illustrates the pouch bein~
positioned between a second pair of heated bars, with the bars in their closed position; and FIGURE 5 illustrates the pouch being finally sealed between a pair of chilled sealing bars.

DETA~LED DESCRIPT10~ OF THE PREFERRED EM8ODIMENTS
- Turning to FI~URE t, a pouch fillin~ and sealing line 1 is illustrated. This line 1 may be a line employing pre-formed pouches 2 as its supply, or the line 1 may include means for forming the pouches 2 from a roll of pouch sheet stoc~. A
- ' .

~ 15775~

typical line 1 for forming, filling and sealing pouches, which may be employed in the practice of the present invention, is a Bartlet* model IMR Intermittent Motion Flexible Pouch Packager, produced by Rexham Corporation.
Since whether the pouches 2 are pre-formed or formed in the filling and sealing apparatus 1 from sheet stock is unimportant to the practice of the present invention, this pouch forming operation is not illustrated in Figure 1. Thus, Figure 1 illustrates the operation from the filling of the pouches 2.
Each pouch 2 is held, as it is positioned from station to station, by means of a pair of grippers 12 and 14. These grippers 12 and 14 are attached to means 10 for positioning the grippers 12 and 14 and the pouch 2 carried therebetween from station to station intermittently. The means 10 may be a chain, belt or the like, and is preferably a chain. This chain 10 is connected to motor means and timing means (not shown) for intermittently moving the chain 10, the grippers 12 and 14 and the pouch 2 from station to station.
The first station illustrated in Figure 1 is a filling station. m e product 4 to be pac~aged within the pouch 2 is fed to the pouch 2 by means of filling means 16. If two or more separate products are to ~e fed to the pouch 2, such as, for example, meat chunks and gra~y, multiple filling stations, each employing a filling means 16, may be used.
The second station illustrated is an air removal position. At this position, a nozzle 18 enters the pouch 2 and superheated steam, at a *trade mar~

- s -~ 157755 temperature preferably between about 250 and 350-F
(121 and 206.5- C~ and at a pressure preferably between about 3 and 7 psi~ (2109.3 and 4921.7 kilograms per square meter) is injec~ed into the pouch 2 to remove air in the pouch 2 prior to sealing thereof.
At the next station, two separate operations occur. First, a nozzle 20 enters the pouch 2. This nozzle 20 has a plurality of openings which direct heated and pressurized steam at the inside of the top edge 6 of the pouch 2 to clean this region 6 of the pouch 2. This is the region 6 of the pouch 2 which is to be heat sealed. The steam employed for cleaning the pouch 2 is supplied at a temperature preferably between about 212 and 275~ (100 and 135-C) and at a pressure preferably between about 15 and 25 psig (10,546.5 and 17,577.5 ~ilograms per square meter). FIGURE 2 illustrates the position of the nozzle-20 as it cleans the pouch

2. Also illustrated in ~IGURE 2 are a pair of heated bars 22 and 23. In F~GU~E 2 these bars are in their open position.
- FI~URE 3 illustrates the nozzle 20 having been retracted out of the pouch 2. At the same time, the heated bars 22 and 23 are closed. Typical means (not shown~ for opening and closing heated ~ars 22 and 23, as well as bars 24, 25, 26 and 27 to - be described below, are adjustable cam-activated arms and the like. Such means comprise a part of the ~nown filling and sealing machines previously mentioned. The bars 22 and 23 are closed to a point with a gap remaining therebetween. That is, while the bars 22 and 23 contact the outside of uppermost edye 6 of the pouch 2, and apply heat to th~s edge 6, no pressure is applied by the bars 22 and 23 to firmly contact the inside surfaces of the pouch 2 and seal the edge 6 of the pouch 2. This permits moisture to evaporate from the sealing edge 6, permitting a final seal to be formed which is free of blisters and other defects. The heated bars 22 and 23 are maintained at a gap preferably between about 0.001 and 0.005 inches (0.00254 and 0.0127 centimeters) greater than the total thickness of the edqe region 6 to be sealed at a temperature preferably between about 200 and 500-P (93.5 and

3~5.5-C), which temperature is chosen to be above the melting point of the thermoplastic resin used ~o form the pouch 2, or forming the inner layer of a laminated pouch 2. The bars 22 and 23 may be heated, for example, by electrical resistance heaters located within the bars 22 and 23 or by other known means.
FIG~RE 4 illustrates an optional, but preferred, additional pair of heated bars 24 and 25 in their closed position. Similar to FIGURES 2 and 3, the pouch 2 is positioned between the bars 24 and 25 while the bars 24 and 25 are open and bars 24 and - 25 25 are then closed. Again, a gap is maintained betwèen the bars 24 and 25, so that no heat sealing pressure is applied to the pouch edge 6. This gap may`préfersbly range between about 0.001 and 0.005 ~nches (0.00254 and 0.0127 centimeters) greater than the total thickness of the edge region 6 to be sealed. The bars 24 and 25 are preferably maintained at a temperature ranging between abo~t 2~0 and 500'F (93.5 and 315.5-C), the temperature again being chosen dependent upon ~he thermoplastic resin employed in forming the inner surface of the pouch 2.
FIGU~E 5 illustra~es the final sealing of the edge 6 of the pouch 2. The pouch 2 is positioned between a pair of chilled sealing bars 26 and 27, which are once again in their open position.
The bars 26 and 27 are then closed, with the edge 6 of the pouch 2 being locked therebetween. The bars 26 and 27 provide a sealing pressure preferably ranging from between about 10 and 100 pounds per square inch (7,301 and 70,310 ~ilograms per square centimeter), dependent upon the material employed as the-inner surface of the pouch 2, on the edge 6 and the heat seal in the ed~e 6 is set and cooled by means of the chilled sealing bars 26 and 27. The chilled sealing bars 26 and 27 each have chambers 28 and 29, respectively, through which a cooling fluid, such as water, is constantly flowed at a temperature preferably ranging ~etween about 50 and 100'F ~10 and 38-C), dependent upon the sheet material employed to form the pouch 2, to cool the bars 26 and 27 and the heat seal in the edge 6 of the pouch 2. me bars 26 and 27 may be bare metal bars, or may be covered with a resilient surface, such as silicone rubber or a Teflon2 impregnated f$berglass cloth or a combination of the resilient surface and the impregnated cloth. At this point, the completed pouch 2 may be transferred from the line and 3~ packaged for shipment.
As previously mentioned, the spaced heated bars 22 and 2~, and optionally 24 and 25, evaporate moisture from the heat seal edge region 6. In . .

~ 1~77~5 addition, it has been found that employment of the spaced heated bars and the pressurizing chilled sealing bars 26 and 27 permits sealing of the edge portion 6 through grease and other contaminants which are not completely removed by the cleaning nozzle 20 and which in the past have caused defective seals. The mechanism for this action is un~nown.
Modifications to the filling and sealing lir.e, while maintaining the gapped heated bars-pressurizing chilled sealing bars method may be accomplished. Thus, for example, the air removal step and cleaning step may be accomplished in a single operation, by means of a single nozzle, which would be located at the position containing the first set of spaced heated bars 22 and 23. Further, additional pairs of gapped heated bars may be employed prior to the pressurizing chilled sealing bars, if desired. The choice as to the number of pairs of gapped heated bars to be employed is determined by the speed of the line, the temperatures of the bars, the material forming the pouch 2 and the material packaged within the pouch 2.
If more than one pair of gapped heated bars are employed, the pair immediately prior to the chilled bars may be vertically positioned slightly higher than the preceeding bar pairs. Whether or ,ç~

~ 15775~
not plural pairs of heated bars are employed, the chilled sealing bars may be vertically offset slightly with respect to one another.
Alternatively, the method of the present invention may be employed with a continuous f illing and sealing machine where pouches pass through a length of heated gapped bars and a chilled sealing mechanism, which may be a pair of chilled bars or a pressurizing chilled roller system.
While presently preferred embodiments of the present invention have been illus~rated and described, it will be understood that the invention may be otherwise variously embodied and practiced within the scope of the following claims.

_ .

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:-

1. A method of heat sealing a flexible container comprising positioning said container between a pair of heated bars, closing said heated bars while maintaining a gap between said heated bars such that heat-sealing pressure is not applied to said container, positioning said container between a pair of chilled sealing bars and closing said chilled bars to apply sealing pressure to said container while sealing and cooling said container.

2. The method of claim 1 wherein said heated bars are maintained at a temperature between about 200 and 500°F (93.5 and 315.5°C).

3. The method of claim 1 wherein said chilled bars are maintained at a temperature between about 50 and 100°F (10 and 38°C).

4. The method of claim 1 wherein said chilled bars apply a sealing pressure between about 10 and 100 pounds per square inch (7,031 and 70,310 kilograms per square meter) to said container.

5. The method of claim 1 wherein said gap between said heated bars is maintained between about 0.001 and 0.005 inches ( 0.00254 and 0.0127 centimeters) greater than the total thickness of said container.

6. The method of claim 1 further comprising positioning said container between at least one additional pair of heated bars and closing said additional heated bars while maintaining a gap between said additional heated bars such that heat-sealing pressure is not applied to said container prior to positioning said container between said chilled bars.

7. The method of claim 7 wherein said additional heated bars are maintained at a temperature between about 200 and 500°F (93.5 and 315.5°C).

8. The method of claim 1 wherein said gap between said additional heated bars is maintained between about 0.001 and 0.005 inches (0.00254 and 0.0127 centimeters) greater than the total thickness of said container.

9. An apparatus for heat sealing a flexible container comprising a pair of heated bars, a pair of chilled sealing bars, means for positioning said container between said heated bars and said chilled bars and means for opening and closing said heated bars and said chilled bars and for maintaining a gap between said heated bars.

10. The apparatus of claim 1 further comprising at least one additional pair of heated bars and means for maintaining a gap between said additional heated bars.

11. The apparatus of claim 9 wherein said heated bars are maintained at a temperature between about 200 and 500°F (93.5 and 315.5°C).

12. The apparatus of claim 10 wherein said additional heated bars are maintained at a temperature between about 200 and 500°F (93.5 and 315.5°C).

13. The apparatus of claim 9 wherein said gap between said heated bars is maintained between about 0.001 and 0.005 inches (0.00254 and 0.0127 centimeters) greater than the total thickness of said container.

14. The apparatus of claim 10 wherein said gap between said additional heated bars is maintained between about 0.001 and 0.005 inches (0.00254 and 0.0127 centimeters) greater than the total thickness of said container.

15. The apparatus of claim 9 wherein said chilled bars are maintained at a temperature between about 50 and 100°F (10 and 38°C).

16. The apparatus of claim 9 wherein said chilled bars apply a sealing pressure between about 10 and 100 pounds per square inch (7,031 and 70,310 kilograms per square meter) to said container.

17. In a method of forming a heat seal on the open end of a flexible container after filling of said flexible container and cleaning of said open end of said flexible container, said cleaning producing moisture on said open end of said flexible container, said flexible container comprising a pair of generally planar walls, which have been heat sealed to one another, comprising positioning said open end of said flexible container between a pair of heated bars and subsequently positioning said open end of said flexible container between a pair of chilled bars the improvement comprising maintaining a sufficient gap between said heated bars such that no pres-sure is applied to said open end of said flexible con-tainer while said open end of said flexible container is positioned between said pair of heated bars, evaporating said moisture from said open end of said flexible con-tainer while said open end of said flexible container is positioned between said pair of heated bars and applying sealing pressure to said open end of said flexible container while cooling said open end of said flexible container while said open end of said flexible container is positioned between said pair of chilled bars to thereby provide a hermatic seal on said open end of said flexible container.

18. The method of claim 17, wherein said heated bars are maintained at a temperature between about 212 and 500°F.
(100.0 and 315.5°C.).

19. The method of claim 17, wherein said chilled bars are maintained at a temperature between about 50 and 100°F.
(10 and 38°C.).

20. The method of claim 17, 18 or 19, wherein said chilled bars apply a sealing pressure between about 10 and 100 pounds per square inch (7,031 and 70,310 kilo-grams per square meter) to said open end of said flexible container.

21. The method of claim 17, 18 or 19, wherein said gap between said heated bars is maintained between about 0.001 and 0.005 inches (0.00254 and 0.0127 centimeters) greater than the total thickness of said flexible con-tainer.

22. The method of claim 17, further comprising positioning said open end of said flexible container between at least one additional pair of heated bars prior to said positioning said open end of said flexible con-tainer between said pair of chilled bars and maintaining a gap between said additional pairs of heated bars such that no presence is applied to said open end of said flexible container prior to said positioning of said flexible container between said pair of chilled bars.

23. The method of claim 22, wherein said additional heated bars are maintained at a temperature between about 212 and 500°F.(100.0 and 315.5°C.).

24. The method of claim 17, 18 or 19, wherein said gap between said additional heated bars is maintained between about 0.001 and 0.005 inches (0.00254 and 0.0127 centimeters) greater than the total thickness of said container.

25. An apparatus for heat sealing a flexible container comprising a pair of directly opposed heated bars, a pair of directly opposed chilled sealing bars, said chilled sealing bars being positioned subsequent to said heated bars, means for sequentially positioning an end portion of said flexible container between said heated bars and said chilled sealing bars and means for opening and closing said heated bars and said chilled sealing bars and for maintaining a gap between said heated bars such that heat sealing pres-sure is not applied to said end portion of said flexible container while said end portion of said flexible con-tainer is positioned between said heated bars.

26. The apparatus of claim 25, further comprising at least one additional pair of directly opposed heated bars positioned between said pair of heated bars and said pair of chilled sealing bars and means for opening and closing said additional heated bars and for maintain-ing a gap between said additional heated bars such that heat sealing pressure is not applied to said end portion of said flexible container while said end portion of said flexible container is positioned between said additional heated bars.

27. The apparatus of claim 25, wherein said heated bars are maintained at a temperature between about 200 and 500°F. (93.3 and 315.5°C.).

28. The apparatus of claim 26, wherein said additional heated bars are maintained at a temperature between about 200 and 500°F. (93.3 and 315.5°C.).

29. The apparatus of claim 25, 26 or 27, wherein said gap between said heated bars is maintained between about 0.001 and 0.005 inches (0.00254 and 0.0127 centi-meters) greater than the total thickness of said con-tainer.

30. The apparatus of claim 26, wherein said gap between said additional heated bars is maintained between about 0.001 and 0.005 inches (0.00254 and 0.0127 centi-meters) greater than the total thickness of said con-tainer.

31. The apparatus of claim 25, 26 or 27, wherein said chilled sealing bars are maintained at a temperature between about 50 and 100°F. (10 and 38°C.).

32. The apparatus of claim 25, 26 or 27, wherein said chilled sealing bars are maintained to apply a seal-ing pressure between about 10 and 100 pounds per square inch (7,031 and 70,310 kilograms per square meter) to said end portion of said flexible container.